EMS by TechniSat The reliable partner for your product idea. From product vision to customised service
With more than 30 years of experience, TechniSat offers in cooperation with the affiliated company TechniForm a complete service from design and material procurement to manufacture and customer service thus generating comprehen sive and sustainable customer satisfaction.
We provide you with support along the entire added-value chain, irrespective of whether you require components, modules or complete units. We provide assistance, from the creation of a customer-specific production layout, through the various sampling phases, right up to the end product. We also invite you to benefit from our tried and tested logistics processes and our many years of experience in international material procurement.
If you wish, you can just select areas of our service range, e.g. tool making or the mere mounting of modules. We are happy to advise you and guarantee a competitive pricing structure for your specific requirements.
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Project management
Development of software, hardware and production layout
Development of test and inspection strategies
Materials and supplier management Tool design and tool making
Programming of integrated circuits Plastic injection moulding
SMD THT SMD and THT, flat module assembly Ultrasonic welding
Soldering processes, depanelisation Robot-assisted module assembly
Test options including 3D paste inspec Painting, printing, hot stamping tion, in-circuit tests, AOI, and many more
Module and product mounting Storage & logistics
Metal stamping, sheet metal forming, Comprehensive service mechanical components
3 Project management
Customer-specific products are developed, tested and produced at the various TechniSat locations in Germany, Europe and Asia. The overriding aims of the company and the business sector within the individual divisions are managed from the company headquarters in Daun, Vulkaneifel.
The project office, which manages customer projects across all locations, is located in Düsseldorf.
The team ensures the maximum utilisation of synergies between the different locations. This is achieved through the implementation and continuous optimisa tion of standardised and flexible processes and production sequences, whilst also complying with customer-relevant requirements.
4 Development of software, hard ware and production layout
Our development engineers‘ exper tise is comprehensive. All fields are covered, from the design (layout and mechanical design) to the deve lopment of hardware and software. The systems/modules can be tested in-house in our own laboratories. This includes endurance tests, EMC tests and checks with regard to reliability, climate resistance, mechanical strength and optical characteristics.
Another decisive factor in the success and economic feasibility of a product is intense and continuous collabora tion between the development and production engineers. When creating the production layout, great emphasis is placed on ensuring that the various development areas are also included in all development phases, with a view to guaranteeing both optimum produ cibility under technical and economic conditions, and guaranteeing that optimum product and process quality are ensured.
5 Development of test and inspection strategies
Comprehensive testing and inspection systems are imperative in order to OPTICAL TEST PROCEDURE guarantee high product quality. We work alongside you to develop an optimum Automatic Optical Inspection (AOI) test and inspection strategy that is adapted to your products and requirements. 3D solder paste inspection The test systems available within our production network cover both manual tests Lighting tests, display tests and optical, electronic and electric inspection systems. ELECTRIC/ELECTRONIC TEST PROCEDURE In-circuit test Boundary scan Functional tests
ADDITIONAL TEST PROCEDURES Screening, testing under extreme climatic conditions in the „climatic chamber“ Endurance tests Various functional tests, etc.
6 Materials and supplier management
We use our central and local procurement offices reliable and qualified suppliers, which has been to search for and qualify reliable suppliers all built up over several years. These have been over the world. Whether hardware and software qualified locally over the years by means of an components or service provision, the require effective supplier development programme and ments we impose on our suppliers are very high, regular auditing. They have also been made but always entirely fair. aware of our customer-specific requirements so that the procurement processes can continue to As well as traditional procurement tasks, we be optimised. Sourcing using the online supplier continuously observe price developments in all platform, developed to suit our requirements, procurement sectors and thus always achieve enables the simple assessment and comparison competitive purchase prices. Contract manage of various quotations. E-auctions round off the ment for all matters surrounding purchasing, advantages of this electronic marketplace. logistics and quality is carried out by our own in-house solicitors. In addition to the central purchasing office in Daun, Vulkaneifel, we also have local procurement Our continuous monitoring process uses teams and competence centres in Asia and Euro individually developed and IT-supported pe. This way we guarantee high flexibility for our processes to evaluate all the necessary supplier customers. Several years of faithful collaboration key performance indicators and thus guarantees with international manufacturers and suppliers effective supplier control and the early detection comes to fruition in the quality and availability of of changes in the market. The experience of our the components and results in competitive price personnel in the field of material procurement management. benefits you, as does our worldwide network of
7 8 Programming of integrated circuits
The automated programming of memory modules, SD cards, micro-controllers and logic modules makes an important contribution to quality and productivity increases in production and enhances our flexibility significantly during the production process. The automatic data I/O programmer with modern FlashCore III technology has 3D lead scanning modules, laser marking and variable input/output media.
SMD and THT flat module assembly
Regardless of the requirement you place on your product, we offer you the equipment required for implementation. Not only do we have more than ten highly technically sophisticated in-house assembly lines, but we are also specialised in meeting the specific requirements involved when dealing with different sectors and batch sizes at the various locations.
9 Soldering process
Various soldering techniques form part of the range of services. In addition to wave soldering and reflow soldering, we also use state-of-the-art selective soldering machines. This is supplemented by the option of manual soldering. We do, of course, solder in compliance with EU Directive 2011/65/EC RoHS on the Restriction of the use of certain hazardous substances when soldering electrical and electronic equipment.
Depanelisation
The separation of PCB panels can be performed using milling or disc shears, while exerting as little stress as possible on the circuit boards. The printed circuit board is fixed in such a way that both the printed circuit board and the components mounted on it are not exposed to any stress during the separation process.
10 Module and product assembly
We offer both manual and semi-automatic assembly, as well as fully automatic customised assembly solutions.
Sheet metal up to a material thickness of 2 mm can be Metal stamping, machined in-house. The design and production of the sheet metal parts are carried out using modern stamping and bending techniques. Series parts can be also be produced sheet metal for on hydraulic presses. ming, mechanical components
11 Tool design and tool construction
By virtue of the several years of experience in the manu facture of plastic products for the sectors of consumer electronics, furniture, music and health care products, our affiliated company, TechniForm, is perfectly positioned to build extremely complex components and tools. The design team uses professional software, working in close collabora tion with the tool making division.
The tool making division is equipped with modern machine tools. For example, this includes Exeron vertical eroding machines, Fanuc wire eroding machines and Hermle 5-axis milling machines. Peripheral machines such as grinding and lathing machines, as well as Zeiss measuring machines, round off the range of machinery.
12 Tool design and tool construction
Plastic injection moulding
The entire production division has, for several years, been specialised in the manufacture of housing parts to meet the strictest of requirements with regard to dimensional accuracy and surface quality.
The modern injection moulding production at TechniForm consists of 15 injection moulding machines with clamping forces between 50 and 750 tonnes. All injection moulding machines are equipped with linear or 6-axis robots to ensure the greatest possible efficiency and process quality. The material is fed automatically via a central drying and conveying system.
13 Ultrasonic welding TechniForm uses ultrasonic welding units to assemble the modules. Compared to other processes, ultrasonic welding is particularly well-suited, especially where short processing times with high process reliability are required, or when no other additives or solvents are to be used. Furthermore, ultrasonic welding is noted for quality, strength and the exact reproducibility of the weld seams.
Robot-assisted module assembly
For automated production, a variety of 6-axis and linear Through the use of modern camera technology, relevant robots can be used if required. In so doing, in addition to quality criteria are already checked during the production high production efficiency, reliable quality is also achieved process. and a high level of repeat accuracy ensured.
14 Finishing
The marketability of your product is significantly influenced by its appearance. That‘s why TechniForm places special emphasis on the visual appearance and initial impression that your product makes on the customer.
Painting Printing Hot stamping
With its fully automatic surface Using modern, digital direct printers, TechniForm offers the hot stamping painting system, TechniForm is able to we can apply and perfectly reproduce process to give your plastic compo paint your components efficiently and any digitisable prints on your product, nents a special finish. This involves in an environmentally-friendly manner, such as motifs, photos, graphics, logos, using pressure and heat to apply a to an excellent quality of finish. Both lettering and the like. Moreover, pad stamping foil, which can feature both water-based and solvent-based paints printing is used for precise printed metallic (e.g. chrome) and organic (e.g. can be used. images in large batches. wood) structures, onto the painted plastic article that is to be decorated. This type of finish offers an excellent alternative to laborious chrome or wood applications.
15 Storage
TechniSat‘s central warehouse is located in the customer and logistics centre in Daun, Vulkaneifel. In addition to this, there are many other storage facilities at the various production locations, which have additional storage space for several thousand pallets and are adapted to specific requirements. Consignment and long-term storage is also possible.
Logistics
As an international EMS service provider, we fully cover your logistics requirements and will create an economical and individual logistics strategy with you for your internal and external logistics processes. We have adequate storage capacity in both central and decentralized locations and are pleased to fulfil individual customer requirements.
16 Comprehensive service
Product and process quality is, of course, structured in such a way that product failures are ruled out as far as possible. However, if complaints are received regarding parts, we also offer an appropriate after-sales service. If you wish, this can include a carefree package, which ranges from the handling of return shipments and the product-specific analysis of customer complaints and guarantee inspections, right up to repairs or the processing of faultless goods to produce new goods by our experienced team of electronics experts.
17 Environmentally friendly production
Environmental conservation is of ever increasing importance nowadays, with many people interested in making the world a little “greener”. As a multinational corporation, we at the TechniGroup are acutely aware of our responsibility to the environment and to society and have made protecting the environment one of the pillars of our corporate philosophy. Because of this we make every effort to realise the whole supply chain from the development to the production as The TechniSat Digital Sp.z o.o has been environmentally friendly as possible and to achieve consistent cuts in energy awarded by the AURAEKO Organisation consumption by our devices. as „environment-friendly company“. One aspect of environmentally friendly production involves eliminating all lead from the production of devices and using only solvent-free coatings and water- based dyes.
Social commitment
TechniSat is committed to the people in the regions in and around its locations. We support societal, cultural and social institutions and actively incorporate workshops for physically, mentally and psychologically impaired persons into the manufacturing process. The workshops are certified in accordance with DIN EN ISO 9001 and carry out some of the equipment assembly. The people are grateful for the fact that they can participate actively in working and thus social life; their thanks is expressed in their careful and precise work.
These workshops for people with disabilities make an outstanding contribution to society with their work, but they are also sustainable enterprises that need to find the correct balance between economic activity and humanity. The needs of the people in the workshops are unique, so processes need to be structured to be both suitable for the disabled and at the same time technically advanced. Quality tests at the end of assembly indicate that this concept is a great success. Several hundred people work in this way for our group and thus find new perspective in their lives.
18 Our quality standards
Certified and partly location-wide quality management systems ensure that our high quality requirements are implemented. Quality policy is continuously monitored and, if required, is adapted to the requirements of the market and the customer. In order to ensure the highest possible product quality at all levels we carry out ongoing internal process audits with the aim of continuous process optimisation. In addition, regular process audits are carried out in close collabora tion with customers.
Experiences gained from continuous Certificate
Standard investigations into product and process ISO 9001:2015
Certificate Registr. No. 01 100 110031
capability are immediately incorpo Certificate Holder: TechniSat Vogtland GmbH
Hauptstr. 46 08261 Schöneck rated into production. Continuous Germany
process optimisation and a correspon
Scope: Manufacture of satellite receiving systems, consumer equipment dingly high level of automation have and accessories as well as customer-specific electronic assemblies and devices permitted us to achieve extremely high
Proof has been furnished by means of an audit that the productivity and efficiency. requirements of ISO 9001:2015 are met. approval. prior
Validity: The certificate is valid from 2017-12-01 until 2020-11-30.
requires First certification 2011
application
and
2017-10-20 Utilisation
TÜV Rheinland Cert GmbH
Am Grauen Stein · 51105 Köln trademarks.
registered
are
TUV
and
www.tuv.com TUEV TÜV,
®
Our expertise in detail
DESIGN & TOOL MAKING OPTICAL TEST PROCEDURE 3D design with SolidWorks Professional Automatic Optical Inspection (AOI) Injection moulding design with the iMold add-on application (for SolidWorks) 3D solder paste inspection CAM with WorkNC for 3-axis and 5-axis milling Lighting tests, display tests Automated erosion with exoprog in combination
with Zeiss DuraMax measuring equipment ELECTRIC/ELECTRONIC TEST PROCEDURE In-circuit test Boundary scan SMD & THT FLAT MODULE ASSEMBLY Functional tests 10 mounting lines for sample, small and large series Pick & place capacity: > 5 billion components p.a. ADDITIONAL TEST PROCEDURES Component sizes ranging from 01005 to 130 mm x 79 mm Screening and testing under extreme climatic conditions in the “climate cabinet” FinePitch-QFP’s, μBGA and many more. Printed circuit boards in sizes from 50 mm x 25 mm (2 × 1“) Endurance tests up to 800 mm x 460 mm (31.5 × 18.11“) Various functional tests, etc.
19 Everything from a single source
Berlin Deutschland Staßfur t
Düsseldorf Schöneck
Daun
TechniSat Digital GmbH, Düsseldorf:
In the Autumn of 2016, our representa tive office was opened in the historical „Dreischeibenhaus“ in the regional capital of Düsseldorf in North Rhine- Westphalia. Düsseldorf is also the base for the EMS project team, which coordinates the acquisition, planning and production of OEM projects.
20 Deutsch- Berlin Polen TechniSat Digital GmbH TechniSat Vogtland GmbH, land Staßfurt Polen Dresden Daun/Vulkaneifel Schöneck/Vogtland ObornikiOborniki Düsseldorf Schöneck
Daun
AbasàrAbasàr UngarnUngarn
China TechniSat Teledigital GmbH, Taishangda Electronics Co., Shenzhen Service Center, Staßfurt Ltd. Shenzhen, China
TechniSat Digital Sp.z o.o, TechniSat Digital Kft. Oborniki, Poland Abasàr bei Budapest, Hungary
21 22 TechniForm
TechniForm GmbH is a company within Techniropa Holding, a group of successful companies that also includes TechniSat Digital GmbH. The company, which has its headquarters in Nerdlen (Vulkaneifel) is an innovative plastics company with its own tool making and design department as well as in-house parts manufacturing, finishing and robot-assisted module assembly.
History
01.09.2009 2013 Launch of the production of housing Start of production for the automotive parts using the injection moulding sector. Production of radio head units. process with three injection moulding machines. 2014 Planning and setup of our own 2010 production halls in Nerdlen. In Decem Expansion of production for the Consu ber, launch of production with the first mer Electronics (CE) sector. By the end test runs. of 2010, expansion to five injection moulding machines. 2015 Completion and full commissioning of 2011 the new site in Nerdlen. Expansion of the production area (rental of a neighbouring hall) by 2016 800 m2, to 1600 m2. Acquisition of Expansion of the production capacities four additional injection moulding with a 400 tonne injection moulding machines. machine, as well as in the areas of pad printing, ultrasonic welding and 2012 robot-assisted module assembly. Expansion of the production depth Expansion into the furniture and health through the relocation of the painting care sector. and printing divisions from the sister plant in Oborniki to Kelberg. Acquisi 2017 tion of another injection moulding Expansion of the machine park to machine (amounting to a total of ten include 15 injection moulding machi injection moulding machines with nes with a clamping force of between clamping forces ranging from 70 to 50 and 750 tonnes, as well as ten 300 tonnes). 6-axis robots and eight linear robots for automated module assembly. Processing of the first orders for the music industry.
23 Contact: Evelyn von Hellfeld Managing director, EMS project manager tel: +49 (0) 211 136502 - 2550 fax: +49 (0) 211 136502 - 2549 email: [email protected]
TechniSat Digital GmbH Dreischeibenhaus 1 40211 Düsseldorf
Further information: www.technisat.de/ems © 2018 by TechniSat Digital GmbH/INFOTECH. Subject to technical changes, typographical errors and mistakes. | m003/1331 201/18 | m003/1331 and mistakes. errors changes, typographical technical to Subject Digital GmbH/INFOTECH. TechniSat by © 2018